Economic Ethanol Fermentation Sugar Stream, Processes and Systems of Producing Same

ABSTRACT

Methods and system for producing a slip stream of sugar, for example for use in the production of one or more chemicals, in ethanol fermentation facilities. In some embodiments, the methods and systems have little to no impact on the level of production of ethanol, despite also producing a slip stream of sugar. The methods and systems can be implemented in dry mill ethanol, wet mill ethanol, and lignocellulosic ethanol fermentation facilities and processes.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S Provisional PatentApplication No. 62/098,434, entitled, “Economic Ethanol FermentationSugar Stream, Processes and Systems of Producing Same,” and having afiling date of Dec. 31, 2014. This provisional application is hereinincorporated by reference in its entirety.

FIELD

The specification relates to methods and systems for producing sugar inethanol fermentation facilities. The specification also relates tomethods and systems for simultaneously producing ethanol and a slipstream of sugar, for example for the production of non-ethanol chemicalsin ethanol fermentation facilities with little to no impact on theethanol facility's alcohol yield.

BACKGROUND

First generation ethanol fermentation facilities produce ethanol fromstarch-based feedstock such as corn. In a typical conventionalcorn-to-ethanol fermentation process, starch present in corn is brokendown into simple sugars, which can be fermented by an ethanologen suchas yeast into ethanol.

Traditional ethanol production processes typically involve five basicsteps: milling, cooking, saccharification, fermentation, distillationand recovery. In some such processes, the milling step is a dry millingstep in which corn is ground into flour. Cooking may involve mixing theflour with water to form a slurry, heating the slurry to above thegelatinization temperature of the corn, and treating the slurry with aliquefying enzyme to hydrolyze starch contained therein to dextrins. Inthe saccharification step, enzymes are added to the mash to convert thecorn starch into simple sugars. The fermentation of the sugars by anethanologen such as yeast produces a beer, which is separated intoethanol and whole stillage by distillation. The whole stillage may besubject to further processing wherein it is separated into wet cake andthin stillage. The thin stillage passes through evaporators to produce asyrup, which may be recombined and dried with the wet cake to producedistillers grains with solubles (DDGS), an animal feed. Not all dry millethanol production processes involve all the identified steps. Forexample, in some dry mill ethanol production processes, saccharificationand fermentation are not independent steps but occur simultaneously. Asanother example, some dry mill ethanol production processes do notinvolve liquefaction. As yet another example, POET®'s BPX® hydrolysisprocess does not use a jet cooker (i.e. a cooking step).

In order to produce a pure sugar stream while also making othercomponents of corn available to sell, some conventional processes use awet mill rather than dry mill approach. In wet milling, corn is soakedin water to soften the grain and facilitate separating the variouscomponents of the corn kernel. After “steeping”, various components suchas starch, fiber and germ are separated from one another for separateprocessing into a variety of products. Fractionation equipment, however,is expensive and increases the cost of producing the sugar stream.

SUMMARY

The present disclosure relates in part to methods and systems forsimultaneously producing a slip stream of sugar stream, for example forthe production of non-ethanol chemicals, as well as a sugar stream forthe production of ethanol in ethanol fermentation facilities whileessentially maintaining the same ethanol titer as could be produced bythe same facility if it did not produce the biochemical sugar stream.

In some such embodiments, the methods involve producing a slip stream ofsugar in an ethanol fermentation facility configured to produce adesired ethanol titer by preparing a fermentable stream from an amountof feedstock, removing a first portion of the fermentable stream priorto fermentation by an ethanologen, and producing ethanol from thesecond, remaining portion of the fermentable stream consistent with thedesired ethanol titer. In some embodiments, the first portion is removedafter saccharification of the fermentable stream. In some embodiments,the first portion is removed prior to saccharification of thefermentable stream.

In some embodiments, the methods are implemented in a first generation(starch-based) ethanol fermentation facility and the fermentable streamis a slurry or a mash. In some further embodiments, wherein thefermentable stream is a mash, the mash is processed to remove solids andproduce a sugar stream. The first generation process may be any processfor converting starch-based materials such as corn into ethanol, forexample including both processes which include and do not include acooking step. In yet further embodiments, the removed solids arereturned to the second portion of the fermentable stream (i.e. mash). Infurther embodiments, the sugar stream is also processed, for example thesugar stream is filtered using a membrane, to remove enzymes and theremoved enzymes are recycled into the second portion of the fermentablestream (i.e. mash).

In other further embodiments, wherein the fermentable stream is aslurry, both the first portion of the slurry is processed into a firstmash and the second portion of the slurry is processed as per usual intoa second mash. In certain further embodiments, the first mash is furtherprocessed to remove solids and produce a sugar stream. In yet furtherembodiments, the removed solids are combined with the second mash. Infurther embodiments, the sugar stream is also processed, for example thesugar stream is filtered using a membrane, to remove enzymes and theremoved enzymes are recycled into the second portion of the fermentablestream (i.e. mash).

In some embodiments, the process is implemented in a lignocellulosic(also referred to as cellulosic) ethanol fermentation facility. Infurther embodiments, the fermentable stream is removed beforesaccharification. In other further embodiments, the fermentable streamis a saccharified liquor and therefore the fermentable stream is removedafter saccharification. In some embodiments, the fermentable stream, forexample the saccharified liquor, is further processed to produce a sugarstream.

In certain embodiments the desired ethanol titer is approximately theethanol-producing facility's maximum titer. For example, in certainembodiments, an amount of feedstock is used which generates afermentable stream (e.g. mash) from which both a first portion forproduction of non-ethanol chemicals and a second portion for productionof ethanol are derived, wherein the second portion is capable ofproducing the maximum titer of ethanol independently of the firstportion. As another example, an amount of feedstock is used whichproduces a fermentable stream that if fermented without separation intoa first portion for production of non-ethanol chemicals and secondportion for production of ethanol would result in an ethanol titer inexcess of what the fermentation facility's ethanologen can tolerate. Insome embodiments, the amount of feedstock ranges from an amount thatwould produce an ethanol titer that is too high for the ethanologen totolerate if both the first fermentable stream (e.g. mash) and secondfermentable stream (e.g. mash) could be fermented in the same tankvolume to an amount of feedstock consistent with the ethanolfermentation facility's capability.

In some embodiments, the systems comprise an ethanol fermentationfacility configured to produce a desired titer of ethanol, andcomponentry configured to remove a slip stream from a fermentable streamproduced in the facility with essentially little or no impact to thedesired ethanol titer production. In some embodiments, the componentryis configured to remove the slip stream after saccharification. In someembodiments the componentry is configured to remove the slip streambefore saccharification. In some embodiments the systems furthercomprise componentry to separate and/or return solids derived from theslip stream back to the ethanol facility, for example back to a mash ora saccharified liquor produced in the facility. In further embodiments,the systems further comprise componentry to separate residual enzymesfrom the sugar stream after removal of solids and return the enzymesback to the ethanol facility. In some embodiments, the facility is astarch-based ethanol facility. In some embodiments, the facility is adry mill starch-based ethanol facility. In some embodiments, thefacility is a dry mill corn-to-ethanol facility. In some embodiments,the facility is a lignocellulosic ethanol facility.

The identified embodiments are exemplary only and are thereforenon-limiting. The details of one or more non-limiting embodimentsaccording to the disclosure are set forth in the descriptions below.Other embodiments according to the disclosure should be apparent tothose of ordinary skill in the art after consideration of the presentdisclosure. For example, although implementations of the processes andsystems are primarily described herein with reference to dry millethanol production processes and systems, they may be adapted to wetmill ethanol processes and systems, as well as lignocellulosic ethanolprocesses and systems as a person of skill in the art would readilyunderstand from reading this specification. Similarly, althoughimplementations of the processes and systems primarily refer tocorn-to-ethanol fermentation processes and systems, they may be adaptedto other biomass-to-ethanol fermentation processes and systems, again asa person of skill could understand from reading this specification.

DETAILED DESCRIPTION

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as is commonly understood by one of ordinary skillin the art to which this disclosure belongs. In the event that there isa plurality of definitions for a term herein, those in this sectionprevail unless stated otherwise.

Where ever the phrases “for example,” “such as,” “including” and thelike are used herein, the phrase “and without limitation” is understoodto follow unless explicitly stated otherwise.

The terms “comprising” and “including” and “involving” (and similarly“comprises” and “includes” and “involves”) are used interchangeably andmean the same thing. Specifically, each of the terms is definedconsistent with the common United States patent law definition of“comprising” and is therefore interpreted to be an open term meaning “atleast the following” and also interpreted not to exclude additionalfeatures, limitations, aspects, etc.

The term “about” is meant to account for variations due to experimentalerror or to permit deviations from the measurements that don'tnegatively impact the intended purpose. All measurements or numbers areimplicitly understood to be modified by the word about, even if themeasurement or number is not explicitly modified by the word about.

The term “substantially” is meant to permit deviations from thedescriptive term that don't negatively impact the intended purpose. Alldescriptive terms are implicitly understood to be modified by the wordsubstantially, even if the descriptive term is not explicitly modifiedby the word substantially.

Where ever the terms “a” or “an” are used, “one or more” is understoodunless explicitly stated otherwise or such interpretation is nonsensicalin context.

The phrases: “essentially maintaining the same ethanol titer”; “withlittle or no impact to the ethanol facility's alcohol yield”;“consistent with the desired ethanol titer” and the like imply that fora given ethanol facility implementing a slip stream sugar processaccording to this disclosure any resulting reduction of ethanolproduction is commercially acceptable. For example, the difference inethanol titer between a facility producing ethanol and a slip stream ofsugar according to this disclosure and the same ethanol facilityproducing ethanol without the slip stream of sugar may be about 10%, orabout 5%, or about 2%, or about 0%.

“Mash” refers to a composition comprising sugar produced in astarch-based facility. “Saccharified liquor” refers to a compositioncomprising sugar produced in a lignocellulosic ethanol facility.“Slurry” refers to a starch composition produced in a starch-basedfacility.

The phrase “sugar stream” refers to a composition that comprises sugar;a sugar stream is not necessarily pure sugar, but may be for example amash or a purified mash (such as a mash that has been processed toremove at least a portion of solids). “Sugar stream” also refers to astream which is diverted from an ethanol fermentation facility toprovide a second source of sugar distinct from the main source of sugarwhich will be used to produce ethanol. Sugar in the sugar stream may beused, for example, to produce one or more chemicals.

The phrases: “removing solids from the first portion of the fermentablestream” and “removing enzymes from the sugar stream” as well as othersimilar phrases suggesting a purification or separation process do notrequire complete removal/separation/purification.

The present disclosure relates to methods and systems for producing asugar stream, for example for use in production of non-ethanolchemicals, while also producing ethanol in a feedstock-to-ethanolfermentation process. In some embodiments, the present disclosureprovides methods and systems for producing a sugar stream, for examplefor use in production of non-ethanol chemicals, while simultaneouslymaintaining ethanol production at a commercially-acceptable level, forexample at essentially maximum titer levels according to theimplementing ethanol fermentation facility's capability.

Ethanol fermentation processes generally involve producing a fermentablestream from a feedstock (for example a grain-based starch feedstockincluding whole cereal such as corn, wheat, sorghum, bulgur, barley) andthereafter producing ethanol from the fermentable stream. For example,in a starch-based ethanol fermentation process, the fermentable streammay be a mash, and producing ethanol involves fermenting sugar in themash into ethanol. As another starch-based example, the fermentablestream may be a slurry, which is saccharified to produce a mash. Thesugar in the mash is thereafter fermented into ethanol. As yet anotherexample, in a lignocellulosic ethanol fermentation process, thefermentable stream may be a saccharified liquor, and producing ethanolinvolves fermenting sugar in the saccharified liquor into ethanol.

In some embodiments, methods described herein generally involveproducing a fermentable stream in excess of what the implementingfacility typically handles or is capable of handling, producing a slipstream of sugar from the excess fermentable stream, and producingethanol from the remaining fermentable stream. In general, the methodsinvolve preparing a fermentable stream from an amount of feedstock,removing a first portion of the fermentable stream prior to fermentationby an ethanologen, and producing ethanol from a second portion of thefermentable stream consistent with the desired ethanol titer.

In some embodiments, the first portion (of the fermentable stream) isremoved after saccharification of the fermentable feed stream. In somesuch embodiments, this sugar slip stream (removed first portion) may befurther purified by removing solids according to any appropriate method,such as any method known to those of ordinary skill in the art. Infurther embodiments, the removed solids are returned to the ethanolfermentation facility and may be recombined with the second portion ofthe fermentation stream or a stream derived from the second portion. Inyet further embodiments, the resultant sugar stream is also subjected toa purification process targeted to remove residual enzymes. In some suchembodiments, the removed residual enzymes are returned for re-use in theethanol fermentation facility, such as recombined with the secondportion of the fermentation stream or other stream derived from thesecond portion.

In some embodiments, the first portion of the fermentable stream isremoved before saccharification of the fermentable stream. In some suchembodiments, the first portion is further processed to produce sugar(such as by being subjected to a saccharification process), and theresultant sugar slip stream may be further purified, for example toremove solids. In further embodiments, the removed solids may berecombined with the second portion of the fermentation stream or astream derived from the second portion.

In some embodiments, the desired ethanol titer is acommercially-acceptable titer. In some embodiments, the desired ethanoltiter is the ethanol producing-facility's maximum ethanol titer.Accordingly, in some embodiments, the amount of feedstock is chosen toproduce the desired ethanol titer that is in excess of the implementingethanol-producing facility's capability if both the first portion of thefermentable stream and second portion of the fermentable stream couldboth be fermented in the same tank. In some embodiments, the amount offeedstock is chosen such that the second portion of the fermentablestream produces the desired ethanol titer. In some such embodiments, theresultant ethanol titer is a commercially-acceptable titer; in othersuch embodiments, the resultant ethanol titer is the ethanol facility'smaximum operational ethanol titer. In some embodiments, the amount offeedstock is chosen to produce an ethanol titer that is greater than theethanologen can tolerate, if both the first portion and second portionof the fermentable stream could be fermented in the same tank. In someembodiments, the chosen amount of feedstock may range from an amountthat produces an ethanol titer greater than the ethanologen can tolerateto an amount that is greater than the implementing facility'scapability. The chosen amount of feedstock may be limited by a givenfacility's operational parameters; a person of ordinary skill coulddetermine the limit based on this specification and knowledge of theoperations of the implementing facility.

In some embodiments, the methods may be implemented in first generation(e.g. starch-based) ethanol fermentation processes, such as a dry millethanol fermentation process. In other words, the “implementingfacility” mentioned throughout may be a first generation ethanolfermentation facility, including facilities which use cooking steps andwhich do not use cooking steps in their hydrolysis process. A dry millcorn ethanol process typically involves: milling corn; slurring the cornwith water; steam exploding the solids; liquefying/saccharifying thestream with enzymes; fermenting the mash; distilling the alcohol fromthe beer; separating the solids form the whole stillage to create wetcake; evaporating some of the water from the thin stillage to createsyrup; removal of oil from the syrup; and, drying the wet cake and thesyrup. However, the processes described herein are not limited inapplication to this typical process but may be applied to all dry millprocesses including, for example, dry mill processes which do not usesteam explosion or other cooking steps. In general, ethanol plants aredesigned to operate as efficiently as possible, i.e. to produce as highan ethanol titer as is possible. Dry mill plants typically producetiters ranging from about 12% to about 20%. Obstacles limiting the titerinclude the ethanologen used to ferment the sugars, and non-fermentablecomponents (“inerts”) produced in the overall process. For example, theethanologen may not be able to tolerate higher titer, and the presenceof a certain level of inerts may impact the yield of alcohol.

In order to produce a stream of sugar while still maintaining theethanol titer, methods according to the present disclosure mill anincreased amount of feedstock relative to the typical amount offeedstock used as input in a given dry mill ethanol fermentationfacility process, and thereby increase the amount of sugar produced inthe mash relative to the amount of sugar produced if the plant were onlyproducing a sugar stream for ethanol. For example, in some dry millembodiments, the amount of feedstock is chosen to produce an ethanoltiter that is in excess of the maximum titer of the given ethanolfermentation facility. For example the amount of feedstock is chosensuch that only a portion of the fermentation stream produced from thefeedstock is required to produce the maximum ethanol titer for the givenethanol fermentation facility. In other dry mill embodiments, the amountof feedstock is chosen to produce an ethanol titer and/or inerts that isgreater than the ethanologen can tolerate. In some dry mill embodiments,the amount of feedstock ranges from an amount that would produce anethanol titer that is too high for the ethanologen to an amount offeedstock consistent with the ethanol fermentation facility'scapability. In some dry mill embodiments, the amount of feedstock may beaugmented above the limits described above by removing one or morecomponents from the feedstock, such as removing fiber from the corn,thereby decreasing the level of inerts entering the fermenter per givenamount of feedstock and allowing for greater grind and sugar removal. Insome embodiments, the removed feedstock components are introduced backinto the system at an appropriate location, such as providing removedcorn fiber to the DDGS.

The additional grind results in a larger portion of fermentable stream,which in some embodiments would produce sugar that exceeds thefermentation facility's processing capability (such as by creatingethanol titers that are too high for the ethanologen to tolerate, orsuch as by producing an amount of inerts that impacts ethanol yieldbeyond what is commercially acceptable). Accordingly, a portion of thefermentable stream is removed prior to fermentation.

In some embodiments, therefore, a first portion of the fermentablestream is removed, for example for the purpose of providing a slipstream of sugar for non-ethanol chemical(s) rather than ethanolproduction, and the second, remaining portion may be fermented intoethanol. In some embodiments, the first portion of mash is removed aftersaccharification. In some dry mill embodiments, the first portion of thefermentable stream is removed after saccharification. Such methods mayinvolve producing a slip stream of sugar in an ethanol fermentationfacility configured to produce a desired ethanol titer by preparing amash from an amount of feedstock, removing a first portion of the mashprior to fermentation by an ethanologen, which corresponds to the slipstream of sugar, and producing ethanol from the second, remainingportion of the mash consistent with the desired ethanol titer.

In other dry mill embodiments, the first portion of the fermentablestream is removed before saccharification. Such methods may involveproducing a slip stream of sugar in an ethanol fermentation facilityconfigured to produce a desired ethanol titer by a preparing a slurryfrom an amount of feedstock, removing a first portion of the slurry,processing the first portion of the slurry to produce a sugar stream(for example directing the slurry to a liquefaction and/orsaccharification process), and producing ethanol from the second,remaining portion of the slurry consistent with the desired ethanol.

The removed mash (whether removed directly as the fermentable stream orgenerated from the removed fermentable stream) may be processedaccording to any method to generate a purified sugar slip stream. Forexample, the removed mash may be processed to separate out solidspresent in the mash, resulting in a sugar slip stream. The sugar slipstream may serve as a source of sugar for production of one or morechemicals. In some embodiments, the separated solids may be combinedwith the mash which is to be fermented to produce ethanol for processingand recovery in the usual course of the facility's operation. In suchembodiments, the level of non-fermentable material (“inerts”) that thefermentation process can handle to maintain desired efficiencies of theethanol process will control the amount of sugar that can be producedfor the chemical sugar slip stream and in turn the amount of additionalinput feedstock that may be used over and above what is used duringusual operation of the facility (i.e. when the facility is operating toonly produce a sugar stream for ethanol production).

In some embodiments, in addition to recycling solids from the firstportion of the fermentable stream, enzymes in the sugar stream are alsorecycled into the ethanol fermentation process. For example, aftersolids are removed, the resultant sugar stream may be subjected to afiltration process to remove enzymes. In some embodiments, recyclingenzymes into the fermentation process from the removed solids and/orfrom the sugar stream provides an economic benefit in that fewer enzymesneed to be used in the ethanol fermentation process. To illustrate thepoint, if: 100% of the enzymes in the slip stream could be recycled; andif the combined volume of the first portion and second portionrepresents 100% of the fermentable volume, with the first portion being20% of the total fermentable volume and the second portion representing80% of the total fermentable volume; then only a quantity of enzymesneeded for 60% of the total fermentable volume needs to be added to thesecond portion because the remaining amount of required enzyme may berecycled into the second portion from the first portion.

In any of the above-described embodiments, the portion of fermentablestream removed may be chosen such that the remaining portion offermentable stream is typical of the amount of fermentable streamprocessed by the given fermentation facility to achieve its desired (forexample maximum) ethanol titer. That is, an amount of sugar may beremoved (directly by removing a portion of the mash or indirectly byremoving a portion of slurry) to maintain the same amount of sugar forthe given facility's typical ethanol production and consequently ethanoltiter.

In some dry mill embodiments, up to about 25% by volume of thefermentable stream (e.g. mash) may be removed prior to fermentation. Insome dry mill embodiments, up to about 15% by volume of the fermentablestream (e.g. mash) may be removed prior to fermentation.

In some dry mill embodiments, up to about 10% by volume of thefermentable stream (e.g. mash) may be removed prior to fermentation. Insome dry mill embodiments, up to about 5% by volume of the fermentablestream (e.g. mash) may be removed prior to fermentation. In some drymill embodiments, from about 10% to about 15% by volume of thefermentable stream (e.g. mash) may be removed prior to fermentation. Insome dry mill embodiments, from about 8% to about 10% by volume of thefermentable stream (e.g. mash) may be removed prior to fermentation. Insome dry mill embodiments, from about 2% to about 5% by volume of thefermentable stream (e.g. mash) may be removed prior to fermentation.

In general, the upper limit of additional fermentable stream (e.g. mash)that may be produced and accordingly the upper limit of fermentablestream (e.g. mash) that may be removed relates to a given facility'sprocessing parameters. For example, facilities that operate at lowertiters may generally be able to grind more and therefore remove morefermentable stream (e.g. mash) relative facilities that operate athigher titer. The amount of additional fermentable stream (e.g. mash)that may be provided to the fermenter also depends on the chosenethanologen and the level of inerts and/or titer it can tolerate. Theamount of fermentable stream (e.g. mash) that may be removed alsodepends on ethanol loss that is acceptable to a given facility. Forexample, if a facility can accept a 10% loss in ethanol, it can removelarger amounts of sugar relative to a facility that desires to maintainits ethanol yield. As another example, if the facility can accept littleto no loss in ethanol and the facility is operating at high titer, itmay only be able to remove a small amount of fermentable stream (e.g.mash) by over grinding.

In some dry mill embodiments, the amount of feedstock may exceed theabove guidelines if one or more components of the feedstock is removedin advance of fermentation, for example in advance of introducing thefeedstock into the process or for example in advance of liquefaction,thereby decreasing the inerts that come into the fermenter permitting agreater grind and mash/sugar removal. As an example, the feedstock maybe corn, and the removed component may be fiber. In some embodiments,the removed component or components, such as fiber, is/are sent directlyto the Dried Distillers Grain (“DDG”). For example, in some suchembodiments wherein components of the feedstock are removed upfront, upto about 37%, or up to about 40% by volume of the fermentable stream maybe removed prior to fermentation.

The present disclosure also provides systems for producing a slip streamof sugar. The systems include an ethanol fermentation facility andcomponentry configured to remove a slip stream from a fermentationstream produced in the facility with essentially no impact to thedesired ethanol titer production. In some embodiments, the ethanolfacility is configured to produce ethanol from a whole cereal, such ascorn. In some embodiments, the ethanol facility is configured to produceethanol from lignocellulosic biomass. In some embodiments, thecomponentry is configured to remove the slip stream aftersaccharification of the fermentable stream. In some embodiments thecomponentry is configured to remove the slip stream beforesaccharification of the fermentable stream. In some embodiments, thesystem provides processing equipment for purifying the slip stream andreturning components removed from the slip stream (such as solidsremoved from mash) back into the stream for production of ethanol (suchas back into the mash in a starch-based facility or back into thesaccharified liquor in a lignocelllulosic facility). In someembodiments, wherein the fermentable stream is removed prior tosaccharification, the system also includes componentry for furtherprocessing of the stream to produce sugar.

A number of embodiments have been described but a person of skillunderstands that still other embodiments are encompassed by thisdisclosure. It will be appreciated by those skilled in the art thatchanges could be made to the embodiments described above withoutdeparting from the broad inventive concepts thereof. For example,although the process is described primarily with respect to dry millprocesses, it could also be adapted to wet mill processes. It isunderstood, therefore, that this disclosure and the inventive conceptsare not limited to the particular embodiments disclosed, but areintended to cover modifications within the spirit and scope of theinventive concepts including as defined in the appended claims.Accordingly, the foregoing description of various embodiments does notnecessarily imply exclusion. For example, “some” embodiments or “other”embodiments may include all or part of “some”, “other,” “further,” and“certain” embodiments within the scope of this invention. Methods anddevices within the scope of the disclosure can also be defined inaccordance with the below embodiments.

Non-Inclusive Additional Embodiments

-   -   1. A process for producing a slip stream of sugar implemented in        an ethanol-producing fermentation facility configured to produce        a desired ethanol titer, comprising:        -   a. preparing a fermentable stream from an amount of            feedstock;        -   b. removing a first portion of the fermentable stream prior            to fermentation by an ethanologen; and,        -   c. producing ethanol from a second portion of the            fermentable stream consistent with the desired ethanol            titer.    -   2. A process according to embodiment 1, wherein the desired        ethanol titer is approximately the ethanol-producing facility's        maximum titer.    -   3. A process according to embodiment 1 or embodiment 2, further        comprising: separating solids from the first portion of the        fermentable stream and providing the solids at least to the        second portion of the fermentable stream to produce a total        amount of solids in the second portion.    -   4. A process according to embodiment 1 or embodiment 2, wherein        the amount of feedstock is chosen to produce an ethanol titer        that is in excess of the maximum titer of the ethanol-producing        facility, if both the first portion and second portion of the        fermentable stream were fermented.    -   5. A process according to embodiment 1 or embodiment 2, wherein        the amount of feedstock is chosen to produce an ethanol titer        that is greater than the ethanologen can tolerate, if both the        first portion and second portion of the fermentable stream were        fermented.    -   6. A process according to embodiment 3, wherein the total amount        of solids in the second portion does not negatively impact the        desired ethanol titer.    -   7. A process according to embodiment 3, wherein the process        maintains the desired ethanol titer.    -   8. A process according to any of embodiments 1-7, wherein the        fermentable stream is chosen from a slurry, a mash, and a        saccharified liquor.    -   9. A process according to embodiment 8, wherein the process is        implemented in a starch-based ethanol fermentation facility and        the fermentable stream is a slurry or a mash.    -   10. A process according to embodiment 9, wherein the first        portion is removed after saccharification and the fermentable        stream is a mash.    -   11. A process according to embodiment 9, wherein the first        portion is removed before saccharification and the fermentable        stream is a slurry.    -   12. A process according to embodiment 10 or embodiment 11,        wherein the feedstock is a whole cereal.    -   13. A process according to embodiment 12, wherein the feedstock        is corn.    -   14. A process according to any of embodiments 6,7, and 9-12,        wherein the process is implemented in a starch-based ethanol        fermentation facility and comprises:        -   a. milling the feedstock;        -   b. cooking the milled feedstock, wherein cooking comprises            mixing the milled feedstock to form a slurry and hydrolyzing            the slurried feedstock to produce dextrins; and, if            necessary,        -   c. saccharifying the dextrins to produce glucose.    -   15. A process according to embodiment 14, wherein the feedstock        has a gelatinazation temperature and hydrolysis is performed        above the gelatinization temperature of the feedstock.    -   16. A process according to embodiment 14, further comprising        fractionating the feedstock.    -   17. A process according to any of embodiments 1-10 and 12-16,        further comprising separating sugar from the first portion of        the fermentable stream.    -   18. A process according to embodiment 17, further comprising        using the sugar to produce one or more chemicals.    -   19. A process according to any of embodiments 1-9 and 11-16,        further comprising directing the first portion to a liquefaction        process, saccharification process or both to produce a mash; and        processing the mash to produce a sugar stream.    -   20. A process according to embodiment 19, wherein the sugar        stream derived from the first portion is used to produce one or        more chemicals.    -   21. A system for producing a slip stream of sugar, comprising:        -   a. an ethanol fermentation facility configured to produce a            desired titer of ethanol from a whole cereal;        -   b. componentry configured to remove a slip stream from a            fermentable stream produced in the facility with essentially            no impact to the desired ethanol titer production.    -   22. A system according to embodiment 21, wherein the desired        ethanol titer is approximately the ethanol fermentation        facility's maximum titer.    -   23. A system according to embodiments 21 or 22, wherein the        componentry is configured to remove the slip stream after        saccharification.    -   24. A system according to embodiments 21 or 22, wherein the        componentry is configured to remove the slip stream before        saccharification.    -   25. A system according to any of embodiments 21-24 further        comprising componentry configured to return solids derived from        the slip stream back to a mash or saccharified liquor produced        in the facility.

What is claimed is:
 1. A process for producing a slip stream of sugar implemented in a dry mill ethanol fermentation facility configured to produce a desired ethanol titer, comprising: a. preparing a fermentable stream from an amount of feedstock, wherein the fermentable stream is chosen from a mash and a slurry; b. removing a first portion of the fermentable stream prior to fermentation by an ethanologen; c. producing ethanol from the remaining portion of the fermentable stream consistent with a desired ethanol titer.
 2. A process according to claim 1, wherein the desired ethanol titer is consistent with the facility's maximum ethanol titer and the second portion of the fermentable stream produces up to the maximum ethanol titer consistent with the fermentation facility's capability.
 3. A process according to claim 1, wherein the fermentable stream is the mash and is removed after saccharification.
 4. A process according to claim 3, further comprising separating solids from the mash to produce a sugar stream; and, combining the separated solids with the second portion of the fermentable stream.
 5. A process according to claim 4, wherein enzymes are separated from the sugar stream and combined with the second portion of the fermentable stream.
 6. A process according to claim 1, wherein the fermentable stream is the slurry and is removed before saccharification.
 7. A process according to claim 6, further comprising processing the slurry to produce a mash; separating solids from the mash; and, combining the separated solids with a mash produced by the second portion of the fermentable stream.
 8. A process according to claim 4, wherein the process maintains the desired ethanol titer.
 9. A process according to claim 1, wherein the feedstock is a whole cereal.
 10. A process according to claim 9, wherein the feedstock is corn.
 11. A process according to claim 10, further comprising fractionating the corn.
 12. A process according to claim 2, wherein the feedstock is corn, the fermentable stream is the mash, the first portion ranges from about 2% to about 5% by volume of the mash, and the process maintains the desired ethanol titer.
 13. A process according to claim 1, wherein the process further comprises using sugar derived from the first portion of the fermentable stream for producing one or more chemicals.
 14. A system for producing a slip stream of sugar, comprising: a. an ethanol fermentation facility configured to produce a desired titer of ethanol from whole cereal; and, b. componentry configured to remove a slip stream from a fermentable stream produced in the fermentation facility with essentially no impact to the desired ethanol titer production.
 15. A system according to claim 14, wherein the componentry is configured to remove the slip stream before saccharification.
 16. A system according to claim 14, wherein the componentry is configured to remove the slip stream after saccharification.
 17. A system according to claim 14, further comprising componentry for returning solids derived from the slip stream back to a mash designated for production of ethanol. 